I-64 Widening

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Pavement Recycling: Segments II & III

Segments II and III Base Pavement Goes Green

VDOT utilized environmentally-friendly processes and recycled materials in both Segment II and Segment III of the I-64 Widening Project, called Cold Central Plant Recycling and Full Depth Reclamation.

VDOT’s research division, the Virginia Transportation Research Council (VTRC) are studying the performance of the pavement recycling techniques through the placement of a forty-foot section of instrumentation sensors in the right wheel path of the right lane during the construction. The sensors will allow researchers to measure the pavement’s performance during its service life and quantify the response to heavy vehicle loads. By confirming the performance of these sections during the service life, VDOT will be able to quickly implement these recycling techniques on other projects.

According to VTRC, this was one of the largest pavement recycling initiatives in the North America currently and second largest in the world, and resulted in an estimated $15 million cost savings total for Segments II and III. Over the course of the I-64 Widening projects, it is estimated that nearly 1.2 million tons of recycled materials were used.

In 2021, the second segment of the I-64 Widening Project was selected as the winner of a 2021 Roads & Bridges/ARRA Recycling Award for their innovative incorporation of recycled materials and the FDR and CCPR processes. This industry award honors the top asphalt road recycling projects in North America.

Cold Central Plant Recycling

Cold Central Plant Recycling (CCPR) was used as part of pavement construction for the new lanes being added to I-64, as well as on the existing lanes that are being reconstructed. CCPR uses reclaimed asphalt pavement (RAP) created from the road millings of construction projects around the region.

To make the CCPR material, RAP and fine stone aggregate are fed into a mobile mixing plant, where the materials are bound together using foamed asphalt and cement, producing up to 220 tons of product per hour. This CCPR mixture is dispensed into dump trucks and hauled to the project site, where crews pave the CCPR on top of an open-graded drainage layer and a subbase layer of FDR material or recycled crushed concrete. In total, these first layers of the pavement structure have a total thickness of nearly 18 inches and are almost entirely produced from recycled materials.

Millions of tons of RAP exist in stockpiles around the state. Not only does using CCPR on this project help reduce stockpiles of existing RAP materials, it also reduces the overall cost of project materials and environmental impacts.

Watch a video showing the CCPR process being used on Segment II below: 

Full Depth Reclamation (FDR)

Full Depth Reclamation (FDR) was used as part of the reconstruction for the existing lanes to create the pavement foundation. As part of the FDR process, the existing pavement foundation is pulverized and mixed with cement onsite, and then recompacted into a subbase layer in the roadway. Costs and environmental impacts are reduced by reusing the already available material. 

The FDR process was also used in the new lanes for the recycled crushed concrete subbase layer, which is using imported crushed concrete from other projects. The FDR layer is covered by a layer of CCPR material.

In the News:

"Reclaiming the Peninsula"
Roads & Bridges Magazine, February 2021

"Recycling Efforts Save Virginia DOT Over $15M on I-64 Rebuild"
Asphalt Contractor Magazine, June 2018

"There's more to I-64 widening project than extra lanes"
Daily Press, August 7, 2017